Simulation Based Optimization of Geometrical Factors and Process Parameters for a Continuous Caster to Fabricate Aluminum Based MMC

Processing of Al-MMC incorporates liquid state processing, specifically, stir casting owing to its simplicity, flexibility and ease of processing. Achieving uniform distribution of reinforcement particles and making the casting process continuous is a tall challenge for the researchers. In the present investigation, a simulation based optimization of various parameters for newly developed continuous casting setup was carried out. Computational simulations were accomplished by Ansys-CFD software. Simulation of various aspects like design, flow behavior, temperature profile, etc., has been studied for optimization of casting process. After analyzing flow pattern of liquid in different conditions, optimized geometry and casting parameters have been proposed. The proposed designed and casting parameters were experimentally validated to synthesize Al-MMC. The experimental result showed that the optimized simulation results can produce sound MMCs with minimum cast defect. Hence, this economical continuous casting process can cast high quality Al MMCs in industrial scale.